Coating material spray gun

ABSTRACT

Control method and apparatus for a manual spray gun may include a second manually actuated trigger disposed on the spray gun handle, with the second trigger being operational to select one or more coating operation parameters.

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. Patent Application is a divisional of U.S. patent applicationSer. No. 14/052,919, filed Oct. 14, 2013, which is a divisional of U.S.patent application Ser. No. 11/981,118 filed on Oct. 31, 2007, theentire disclosures of which are fully incorporated herein by reference.

TECHNICAL FIELD OF THE DISCLOSURE

The disclosure relates to the art of applying material onto surfaces,such as for example, spraying or coating a surface with a coatingmaterial. More particularly, the disclosure and inventions relate toarrangements and methods for controlling a material application devicesuch as, for example, a spray gun.

BACKGROUND

Powder coating material such as powder paint is commonly applied to anobject by spraying the powder coating material. Typically, a spray gunor material application device is used, and spray guns may be manuallyheld and operated or automatic spray guns may be used that arecontrolled electronically. For manual spray guns, a trigger type deviceis commonly disposed on the handle so that an operator can fingeractuate the trigger to start and stop a coating operation. It is knownto provide a separate trigger or switch on the spray gun handle toinitiate a purge operation.

Spray technologies include for example electrostatic, non-electrostaticand tribo-electric. The powder flow path through a spray gun must bepurged whenever the powder coating material, such as its color or othercharacteristic, is changed, in order to prevent unwanted contamination.In addition, various parameters are commonly changed for different partsbeing coated or when different coating materials are used. Suchchangeovers result in lost production time.

SUMMARY OF THE DISCLOSURE

The present disclosure presents a number of inventive aspects for bothapparatus and methods relating to controlling a coating materialapplication device. In accordance with one inventive aspect of thedisclosure, a selection or auxiliary device is provided that allows anoperator to select one or more coating operation parameters eitherbefore, during, between or after coating operations, or in oneembodiment, during operation of the material application deviceincluding optionally during a coating material operation. In oneembodiment, the device may be realized in the form of a manuallyactuated device that may be used to make adjustments or selections orchanges to one or more coating operation parameters. In an exemplaryembodiment, the manually actuated device may be in the form of a fingeractuated trigger disposed on a handgrip of a manually operated spraygun. Examples of coating operation parameters may include but notlimited to flow rate of the coating material, flow rate of the air thatproduces a flow of coating material, and preset coating operationrecipes. The manually actuated device may be in addition to a secondmanually actuated device disposed on the handgrip such as for example asecond trigger that may be used, as one example, to control the on/offoperation of the material application device. Functionality associatedwith actuation of the auxiliary device may be programmable for specificcontrol features desired in particular applications and uses.

In accordance with another inventive aspect of the disclosure, a firstcontroller function may be provided that is associated with a materialapplication device, such as a controller disposed in or on or with amaterial application device. A second controller function may also beprovided that is external or remote from the material applicationdevice, such as for example a system controller function that controlsoperation of various components including but not limited to one or morepumps, feed centers, vibrators, overspray recovery systems, spray boothrelated controls and so on. The first controller and second controllermay communicate with each other, for example over a network, so that aselection or auxiliary device functions to control the one or morecoating operation parameters. For example, a trigger may be used toadjust flow rate of the coating material from a spray gun. In anotherembodiment, the second controller may be used to program or update thesoftware for the first controller. The second controller may optionallybe used to change or program the functionality that is associated withactuation of the selection or auxiliary device.

The disclosure also contemplates methods embodied in the use of suchapparatus. The disclosure further presents inventive methods including amethod for controlling a coating material application system thatincludes a material application device that is manually held andoperated during a coating operation, the method in one embodimentincluding the steps of manually holding a handgrip of the materialapplication device with one hand, and using the same hand while grippingthe material application device to select at least one coating operationparameter.

Further inventive aspects, advantages and benefits will become apparentto those skilled in the art after considering the following descriptionin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric illustration of one embodiment of a materialapplication device, in a material application system, that incorporatesone or more inventive aspects of the present disclosure;

FIG. 2 is an elevation of the embodiment of the material applicationdevice of FIG. 1, shown in longitudinal cross-section;

FIG. 3 is an enlarged view of the corresponding region circled in FIG.2;

FIG. 4 is an enlarged view of the corresponding region circled in FIG.2;

FIG. 5 is a rear view of the material application device of FIG. 1showing a display;

FIG. 6 is an exemplary and simplified illustration of a display as itmight appear in use;

FIG. 7 is a functional block diagram of a display controller and relatedcircuits;

FIG. 8 is a functional block diagram of a system controller and relatedcircuits;

FIG. 9A is an exploded perspective of a trigger and switch arrangementfor the embodiment of FIG. 1; and

FIG. 9B is another view of the trigger member of FIG. 9A.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The inventions described herein are explained and illustrated in thecontext of a powder coating material application device, such as, forexample, an electrostatic powder spray gun. However, the exemplaryembodiments are not intended to be a limitation on the application oruse of the various inventive aspects presented in this disclosure. Forexample, the inventions may be used with non-electrostatic materialapplication devices and with tribo-charging guns that do not utilize anelectrode, or combinations thereof. The inventions also are not limitedto any particular type or use of coating material. Additionally, theterms ‘spray’ and ‘spray pattern’ are intended to be understood in theirbroadest meaning to include not only those processes commonly referredto as ‘spray’ or ‘spraying’ but additionally any application techniqueinvolving the directing of a generally dry particulate coating materialacross a space towards a target. The spray pattern may be but need notbe atomized. When used, atomization may be based on pressure, air, orboth or other atomization techniques and combinations thereof. Stillfurther, the terms ‘spray’ and ‘spray patterns’ are not to be limited toany particular time duration that the material is directed towards thetarget. In other words, very short bursts of material or narrow jets ofmaterial are still to be construed as falling within the understandingherein of the word ‘spray’ and ‘spray pattern’. While the inventions arealso described and illustrated herein with reference to an exemplaryspray gun configuration, shape and arrangement, nothing herein should beconstrued as limiting the inventions o such embodiments. Many differentconfigurations and designs may be used, far too many to identify ordescribe herein.

As used herein, a purge operation refers to stopping flow of coatingmaterial from a material supply to a material application device, andapplying pressurized purge air through part or all of the coatingmaterial flow path to remove as much of the coating material from theflow path as can be achieved for a given purging system design. As usedherein, a coating operation refers to a set of events and/or varioussteps and operations that occur in order for a coating material to beapplied to one or more objects. Thus the term coating operation isgenerally inclusive of one or more, and typically many, operations,functions, settings and conditions that determine the application ofmaterial to an object. For example, but not by way of limitation, acoating operation may include supply pump operation, spray booth andoverspray recovery operations, conveyor system control, electrostaticcontrol functions, material flow rates, atomization and flow aircontrol, coating material characteristics and so on. For any particularcoating operation then, there may be as few as one, but typically manyparameters that are controlled or set, or in many cases are adjustedwhen coating operations are changed. These coating operation parametersmay include but are not limited to, for example, voltage and current forelectrostatic operations, coating material flow rates, air flow rates,purge timing and flow, as well as many other operations, functions,settings and conditions related to a coating operation. Therefore, theterm coating operation parameter should be broadly construed asreferring to any information, control, function, input, output,operation, setting, condition or feature related to a coating operationthat affects or influences a coating operation. The various parametersor subsets thereof, associated with a specific coating operation aregenerally referred to herein as recipes or coating operation recipes,and such recipes are typically, though need not be, predetermined andstored in memory for access by a main control system which controls thevarious system components to execute a coating operation in accordancewith a selected recipe. Usually recipes are fixed as far as a lineoperator is concerned, but some systems may be designed to permit recipechanges and other variations by any personnel with proper authority tomake such changes. Thus as used herein, recipe is not intended to belimited to a set of parameters that cannot be changed, but may includerecipes in which one or more parameters, instructions, controls andfunctions may be changed. The term recipe thus also includes recipesthat are predetermined or preset, as well as recipes that are puttogether on a more real time basis before a coating operation, ormodified prior to a coating operation.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, software,hardware, control logic, alternatives as to form, fit and function, andso on—may be described herein, such descriptions are not intended to bea complete or exhaustive list of available alternative embodiments,whether presently known or later developed. Those skilled in the art mayreadily adopt one or more of the inventive aspects, concepts or featuresinto additional embodiments and uses within the scope of the presentinventions even if such embodiments are not expressly disclosed herein.Additionally, even though some features, concepts or aspects of theinventions may be described herein as being a preferred arrangement ormethod, such description is not intended to suggest that such feature isrequired or necessary unless expressly so stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure; however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention, the scope of the inventions instead being set forth in theappended claims or the claims of related or continuing applications.Descriptions of exemplary methods or processes are not limited toinclusion of all steps as being required in all cases, nor is the orderthat the steps are presented to be construed as required or necessaryunless expressly so stated.

With reference to FIG. 1, a manually operated material applicationdevice 10 may include a nozzle portion 12, a barrel portion 14 and ahandgrip portion 16. In the examples herein, the device 10 may be, forexample, any suitable material application device or spray gun. Theterms spray gun and material application device are used hereininterchangeably, however, it is to be understood that a materialapplication device may be realized in many forms other than just a spraygun and is not limited to that terminology. Typically, the nozzleportion 12, barrel portion 14 and handgrip portion 16 are eachmulti-piece assemblies, and also separable from each other. However, thepresent disclosure and the inventions herein are not limited to anyparticular design, shape or configuration of the material applicationdevice 10 or its constituent parts, including the design, shape orconfiguration of the handgrip portion 16, and may include machinedparts, molded parts, combinations thereof, integrated portions and soon. In some descriptions herein, general reference may be made to amaterial application device body or device body, by which is meant anypart or combination of parts that form portions or all of the structureof the application device, such as for example, the handgrip portion 16,the barrel portion 14 and the nozzle portion 12. The various inventionsand inventive aspects of the disclosure may be realized in far toonumerous ways and configurations of the handgrip portion 16, as well asthe barrel portion 14 and nozzle portion 12 to identify and discloseherein.

The handgrip portion 16 may be realized, for example, in the form of ahandle 18 that is manually held or gripped during operation of the spraygun 10. For electrostatic devices 10, the handle 18 may include aportion that contacts the operator's hand and is grounded. For purposesof this description, the term handgrip is generally used to refer to anystructure or assembly or member that is manually held or gripped by anoperator during operation of the application device 10 to support andcontrol the device 10, with a handle, grip or other structure beingexemplary embodiments of such a handgrip.

As illustrated in FIG. 1, a coating material supply 20 may be used as asource of coating material to the spray gun 10. A feed or supply hose 22is commonly used to connect the spray gun 10 with the supply 20. A hoseconnector 24 may be provided to securely attach the supply hose 22 tothe spray gun. In the case of an electrostatic spray gun as shown inFIG. 1, an electrical control cable or connection 26 may be providedbetween a control system 28 and an electrical input 30 of the spray gun.The control system 28 may also receive one or more signals from thespray gun 10, such as for example a trigger actuation signal thatindicates that the operator has activated a first manually actuateddevice 32. In the exemplary embodiment, the first manually actuateddevice may be realized, for example, in the form of a main trigger orswitch 32 to initiate a coating operation. The main trigger 32 may bedesigned so that an operator is able to actuate the trigger 32 using afinger of the same hand that the operator is using to hold the spray gun10 via the handgrip portion 16. By ‘main’ trigger is simply meant thatthe primary function associated with the first trigger 32, but notnecessarily the only function, is to control on/off operation of thespray gun for a coating operation. When the main trigger 32 isactivated, an electrical signal or condition (such as closed contacts)is sent to or detected by the control system 28 to begin flow of coatingmaterial to the spray gun 10, and other signals may be generated toactivate electrical power for the spray gun (in the case ofelectrostatic operation for example). In the exemplary embodiment, theelectrical signal or condition that is associated with actuation of themain trigger 32 is coupled to and detected initially by a displaycontroller 110 (see FIG. 4 herein), which will be explained in greaterdetail herein below. The display controller 110 communicates with thecontrol system 28 over a network, so that the control system 28 detectsactuation of the main trigger 32 via the display controller and network.Alternatively, the main trigger 32 actuation may be coupled to thecontrol system 28 other than through the network, for example, by awired or wireless connection directly between the main trigger 32 andthe control system 28.

All electrical signals or conditions between the spray gun 10 and thecontrol system 28 or other system components may be transmitted alongelectrical lines through the electrical cable 26. Alternatively, signalsmay be transmitted using wireless techniques including RF, IR opticaland so on. In the embodiments herein that include the use of a networkto link the material application device 10 with the control system 28,the network wiring (single wire or multi-wire) may also pass through theelectrical cable 26.

The control system 28 may be any suitable arrangement as is well knownin the art for controlling input power and operation of the spray gunelectrical requirements, as well as controlling operation of the coatingmaterial supply 20, a purge supply 34 and other system related featuressuch as a spray booth, parts conveyor and so on (not shown). Thematerial supply 20 forms no part of the present inventions except asused in combination with the apparatus and methods as set forth herein.The coating material supply 20 typically includes a pump or pumps underthe control of the control system 28 so that the control system 28starts the pump in response to the operator actuating the trigger 32.This causes coating material to flow through the handgrip portion 18,the barrel portion 14 and out through the nozzle portion 12 to form adesired spray pattern S, typically in the form of a cloud like patternfor powder coating material, for example.

A purge supply 34 under the control of the control system 28 may be usedto provide pressurized purge air or other gas through a purge hose 36 tothe spray gun 10. The purge hose 36 may be connectable to a suitablehose connector input 38 disposed on the handgrip 16, and in this examplea base 40 of the handle 18. The purge air inlet to the handgrip 16 maythus be separate from the coating material input at the hose connector24, so that purge air initially enters a coating material flow path (notshown in FIG. 1) by first passing through a purge air flow path withinthe handgrip 16. The present inventions however are not limited to anyparticular purging arrangement or coating material flow patharrangement. For example, purge air may alternatively be introduced intothe coating material flow path near or at the supply 20, or even upcloser to the barrel portion or the nozzle portion 12, to name a fewexamples. The present inventions are also not limited to a coatingmaterial flow path that begins at the base of the handle 40. In many gundesigns, the material flow path first enters the gun up at the barrelportion, for example.

FIG. 2 illustrates the application device 10 in longitudinalcross-section. As shown, the handle 18 may be ergonomically contoured toease strain on the operator's hand during prolonged operation or shifts.The coating material hose connector 24 has a first end 42 adapted toreceive one end of the supply hose 22 (not shown) and an opposite end 44that telescopically slides into a first end 46 of an inlet tube 48.

The inlet tube 48 extends up through the handle 18 and mates, such asfor example with a telescopic connection, with one end of an elbowadapter 50. The elbow adapter 50 has another end that mates with, suchas for example with a telescopic connection, a first end of an outlettube 52. The outlet tube 52 extends along the barrel portion 14 to thenozzle portion 12 so that coating material exits through the distal endof the outlet tube, and into and through the nozzle portion 12 to formthe spray pattern S. The details of the nozzle portion 12 are not neededfor understanding and practicing the inventions of this disclosure. Inalternative designs, for example, the outlet tube 52 may itself form orprovide an outlet orifice through which coating material exits thenozzle. In the exemplary embodiments herein, the nozzle portion 12 mayinclude an electrode assembly 54 that is charged by an internal powersupply section 56 in the rearward portion of the barrel 14. The supply56 typically is realized in the form of a high voltage multiplier andrelated circuits as is well known. Many different types of electrodeassemblies may be used, including electrode tips that are positionedoutside the nozzle portion 12, as well as many different types of powersupply designs, configurations and locations, including external powersupplies and hybrid designs with portions of the power supply externalthe spray gun 10 and other portions internal the spray gun 10. Anelectrode air wash inlet 58 may be provided that is connectable to asource of pressurized air, with an air passageway (not shown) thatextends up through the handle 18, along the barrel portion 14 and intothe nozzle portion 12 so as to provide a flow of air across the nozzletip to help prevent the accumulation of coating material on the nozzletip.

The inlet tube 48, the elbow 50 and the outlet tube 52 thus combine toform or define a coating material flow path—in the exemplary embodimentbeing formed by the interior volume of the inlet tube 48, the elbow 50and outlet tube 52 (and as represented by the arrows associated with thenumeral 60)—that extends from the handle 18, along the barrel portion 14to the nozzle portion 12.

In accordance with an inventive aspect of the present disclosure, asecond manually actuated device 70 may be provided. This second manuallyactuated device 70 may be realized, for example, in the form of a secondor auxiliary trigger or switch. Preferably, although not necessarily,the auxiliary trigger 70 may be finger actuated, and in particular witha finger of the operator's hand that is also holding the spray gunhandle 18. Separate fingers may be but need not be used to actuate thefirst and second triggers 32, 70.

With reference to FIGS. 3, 9A and 9B, the main trigger 32 and theauxiliary trigger 70 may be operably coupled to actuate membraneswitches or other suitable switch designs. The main trigger 32 in thisexample includes main trigger body 72 having a pair of flexible arms 74extending there from. A distal end 76 of each flexible arm 74 engagesone side of a membrane switch assembly 78, near a membrane switch 80that is associated with the main trigger 32, such as at locations 76 aand 76 b on opposite sides of the membrane switch 80. The distal ends 76may alternatively engage any other conveniently available surface thatwill provide adequate support so that the legs 74 may be compressedinward when the main trigger body 72 is pulled toward the handle 18 toactuate the main trigger 32.

In this example, the membrane switch assembly 78 includes three membraneswitches 80, 96 and 98. The lower switch 80 may be used to detectactuation of the main trigger 32, which the upper two switches 96 and 98may be used to detect actuation of the auxiliary trigger 70 (as will befurther explained herein below). The various membrane switches may bedisposed on a board 78 a, although the membrane switches may beinstalled in the spray gun in any other convenient manner as desired.

The main trigger body 72 may further include an inwardly facing hollowboss 73 that receives and retains a softer actuating post 75. Theactuating post 75 is sized so that when it is fully inserted inside theboss 73, and end portion 75 a extends slightly out beyond the end of theboss 73. The end portion 75 a engages the associated membrane switch 80to actuate the switch 80 when the main trigger body 72 is pulled by theoperator. The main trigger body 72 may be attached to the handle 18 byany convenient means, such as pivot posts 77 a on the handle 18 (onlyone shown in FIG. 9A) and cooperating holes 77 b on the main triggerbody 72. The posts 77 a may also be used to support the auxiliarytrigger 70 on the handle 18. The main trigger body 72 may furtherinclude a window 79 through which the auxiliary trigger 70 may extendafter assembly. In this manner, an operator may easily access bothtriggers 32 and 70 with one finger if so desired.

When the trigger 32 is pulled inward (leftward as viewed in FIGS. 3 and9A, the distal end 75 a of the actuating post 75 presses against aflexible contact portion 80 a of the membrane switch 80, which makeselectrical contact with a stationary contact portion 82 (FIG. 3). Thiselectrical contact or connection provides an indication to the controlsystem 28 to start a coating operation. When the trigger 32 is releasedby the operator, the spring like bias of the flexible arms 74 pushes thetrigger body 72 back to its deactivated position shown in FIG. 3,withdrawing the post 75 far enough away from the switch 80 so that theflexible contact portion 80 a snaps back or moves away from and out ofcontact with the stationary contact portion 82, thereby signaling to thecontrol system 28 to stop a coating operation. When the main trigger 32is released, the post 75 may but need not remain in actual contact withthe flexible contact 80 a.

The use of the post 75 has a number of advantages. Preferably, the postmay be made of a softer material, such as rubber for example, so thatthe operator receives a softer tactile feedback for more comfort. Bysimply changing the relative hardness or softness of the post, the feelcan be changed. The use of a soft post 75 such as rubber material alsoallows the post 75 to compress so as to reduce damage on the switch 80due to over travel or excessive force applied to the trigger 32. The useof the two flexible arms 74 provides redundancy. Should one of the armsbecome damaged or break, the other arm will still allow the trigger 32to function, and in particular will assure that the switch 80 is openedwhen the trigger 32 is released.

The auxiliary trigger 70 in this embodiment may be a dual switchingdevice in which the auxiliary trigger 70 has a neutral or deactivatedposition illustrated in FIG. 3, a first actuated position and a secondactuated position. However, the present inventions are not limited inany manner to a particular trigger configuration nor to a singleauxiliary trigger. The auxiliary trigger may have more than two actuatedpositions, or there could be more than one such auxiliary trigger. As anexample, the manually actuated device 70 may be a slide switch withmultiple positions or a rotary switch with multiple positions, or ajoystick with multiple positions, and so on. In any case, the auxiliarytrigger/switch 70 design will be determined by the total functionalitythat is to be carried out by operator use of such devices.

The auxiliary trigger 70 may include a finger engageable lever 84 thatextends from a central hub 86. The hub 86 may include a spring or otherdevice (not shown) that normally urges the trigger 70 to the neutralposition, meaning that a force needs to be applied to the trigger 70 inorder to actuate a related switch. Extending from the hub 86 are firstand second actuation arms 88 and 90 that may engage but need not engagerespective flexible contacts 92 and 94 of respective upper and lowermembrane switches 96 and 98 when the trigger 70 is in the neutralposition. Thus, when the auxiliary trigger 70 is pivoted upward asviewed in FIG. 3, the first actuation arm 88 presses against itsassociated flexible contact 92 to close the upper membrane switch 96.Similarly, when the trigger 70 is pivoted downward as viewed in FIG. 3,the second actuation arm 90 presses against its associated flexiblecontact 94 to close the lower membrane switch 98. It should be notedthat an operator may easily actuate the auxiliary trigger 70 while themain trigger 32 is either also actuated or when it is not actuated. Themembrane switches 96, 98 when actuated indicate to the control systemthat a desired action or function is to occur. As with the main triggerswitch 80, the corresponding electrical signals or conditions for theauxiliary trigger switches 96, 98 are communicated to the control system28 via the display controller 110 and the network 112 (FIG. 1).Alternatively, these signals may be communicated in a wireless manner orthrough wires along the electrical cable 26.

For example, the control system 28 may include instructions such as insoftware or otherwise, that the up/down actuation of the auxiliarytrigger 70 relates to a command to increment or decrement a coatingoperation parameter. Alternatively, the auxiliary trigger actuation maybe used to scroll through a list of available choices for changing orselecting one or more coating operation parameters. Many otheralternative functions and controls may be associated with actuation ofthe auxiliary trigger 70, far too many to list herein. Moreover, thefunctionality of the auxiliary trigger 70 may change for differentoperating modes of the spray gun 10 or the system. For example, during acoating operation, actuation of the auxiliary trigger 70 may increase ordecrease material flow rate, but during a purge operation the triggermay be used for shutdown or standby modes. Additional features andfunctions will be described in greater detail herein below.

With reference to FIGS. 2 and 4, in accordance with another inventiveaspect of the present disclosure, a visual information device, such as adisplay 100, is provided for presenting information to an operatorconcerning one or more operating parameters or other information aboutthe spray gun 10, one or more of the system components such as the purgesupply 34, the material supply system 20 and so on. Preferably, thedisplay 100 is disposed on or with a portion of the spray gun. In theexemplary embodiment, the display 100 may be installed at the back endof the barrel portion 14, so as to be easily visible to an operatorwhile the operator is using the spray gun.

The display 100 may be conveniently attached or recessed within the gunbody, in this example just aft of the power supply section 56. Aprotective viewing collar 102 may be used so that the display isprotected from adverse impact and contamination, and also perhaps insome situations more easily viewed. A protective lens or cover 104 mayfurther be provided, and the lens 104 may include appropriate legendsand markings for facilitating use of the display 100 as needed. Thedisplay 100 may further include a visual indicator device 106, such as apair of seven segment LEDs for example, and one or more circuit boards108 that may contain a display controller 110 and related and additionalcircuitry. The display controller 110 performs over all controlfunctions for the display 100, and may also include a network interfaceso that the display controller 110 may communicate over a network 112(see FIG. 1) with a main controller 114 associated with the controlsystem 28. A suitable network may be a single wire network such as forexample a LIN network (the single wire passing through the electricalcable 26 for example), but any network including multi-wire and wirelessmay alternatively be used as needed. In the exemplary embodiment, thedisplay 100 may also include one or more manually actuated inputs 116,such as, for example, pushbutton membrane switches. The manual inputs116, however, may alternatively be disposed elsewhere on the applicationdevice.

With reference to FIGS. 5 and 6, the display 100 manually actuatedinputs 116 may include first and second pushbutton membrane switches 118and 120, for example, although any switch or selector device may be usedas needed. Also, the visual indicator device 106 may include first andsecond seven segment LED displays 122 and 124. Although the displays 122and 124 in this example are numeric, other displays includingalphanumeric, LCD and others may be used that are suitable to conveyinformation desired to be displayed to an operator. Additional visualindicators may be used as desired. For example, first and second lamps,such as LED's, 126 and 128 may be used for illuminating associated icons130 and 132 (FIG. 6).

As an example, one of the manually actuated inputs 116 may be used as aMode selection switch 118. The other manually actuated input may be usedas a Purge Start switch 120. When the Purge Start switch 120 isactuated, an indication is sent to the control system 28 over thenetwork 112 and the control system 28 initiates a purge operation. Whenthe Purge Start switch 120 is not activated, the system may be in astandby condition or a coating operation condition, or other conditionas desired. Purge operations may be initiated in other ways besides useof the second input 120. For example, the control system 28 may beprogrammed to recognize that when the auxiliary trigger 70 is actuated,a purge operation begins. This allows an operator with one hand tocontrol a coating operation and a purge operation. In such a case, thesecond input 120 may be programmed to perform another function, such asa system shutdown, a reset or any other desired action or operation.

The display 100 in some systems may have its own functionality forpresenting information to an operator about any number or type of systemrelated data and parameters. For example, the display controller 110 maybe programmed to simply display material flow rate during a coatingoperation based on data received from control system 28 over the network112. Material flow rate may be expressed, for example, in grams perminute, or as a percentage of maximum flow rate, to give two examples.Material flow rate may also be extrapolated from air flow values, suchas flow air rate.

However, it is further contemplated that the display 100 may be used togreatly enhance the flexibility and functionality of the auxiliarytrigger 70. Since the auxiliary trigger 70 may be a multiple inputdevice, it may be used to control what information is displayed and tomake selections from a listing of options. As an example, the ModeSelect button 118 may be used to select different display modes for thedisplay 100. In one embodiment, pressing the Mode switch 118 places thedevice in a flow rate mode which causes the second icon 132 lamp 128 tobe illuminated. Pressing the Mode switch 118 again extinguishes thesecond icon 132 lamp and illuminates the lamp 126 for the first icon130, which places the device in a Folder display mode. Each successiveactuation of the Mode button toggles the display between Folder Mode andFlow Rate Mode.

In the Folder display mode, the operator may next use the auxiliarytrigger 70 to scroll up and down or forward and backward through a listof coating operation preset recipes. Each actuation of the auxiliarytrigger 70 presents a new preset number to the operator via the visualindicator device 106. In the example of FIG. 6, the display is in theFolder Mode, and preset 02 is being displayed. If the operator leavesthe display at preset 02, then the control system 28 will initiate thedesired operating parameters for that preset recipe. The operator doesnot need to necessarily know what all parameters and conditions will beadjusted for that particular recipe, only that this is the recipe eithercalled for or that is working best for the particular coating operation.Optionally, only preset numbers that actually have informationassociated with them need be displayed to the operator.

In the Flow Rate Mode, the associated icon 132 is illuminated so theoperator knows which mode is being used. In this example, the visualindicator device 106 now may display flow rate for the coating materialthrough the spray gun 10 This information for example may be sent fromthe control system 28 over the network 112 to the display controller110. When in the Flow Rate Mode, the operator may actuate the auxiliarytrigger 70 up and down as desired to increase or decrease the flow rateparameter. Since this functionality is independent of the main trigger32, the operator can initiate these selections even while actuallyperforming a coating operation or just prior to or after a coatingoperation, as the case may be.

The display 100 greatly enhances this functionality of the auxiliarytrigger 70 because it allows the operator to visually observe theinformation related to the selected mode of operation, and in also toview options, make selections and view confirmation of the selections,without having to divert attention or field of view away from the spraygun 10 or the object being coated. This allows one or more operatingparameters to be changed or selected without interrupting a particularcoating operation, or at least without having to look away from thespray gun or coating area in order to implement such changes, selectionsand to confirm the selection made. For example, in the Flow Rate Mode,the operator can simply actuate the auxiliary trigger 70 up or down asneeded to adjust or select flow rate during a coating operation toimprove the product finish. Or the operator may switch preset recipes asa new object to be coated enters the coating area, or if the currentpreset is not adequately coating the object. Alternatively, the systemmay be programmed to allow selections, such as flow rates or presetrecipe select or purge initiation for example, when the main trigger 32is not actuated. Still further, the functions and controls that areassociated with actuation of the auxiliary trigger 70 may be a functionof whether the main trigger 32 is actuated or not, and further afunction of what mode is selected via the manual inputs 116. Forexample, if the main trigger 32 is actuated, the auxiliary trigger willnot be able to initiate a purge operation.

Thus, the combined functionality of the auxiliary trigger 70 and thedisplay 100 allows an operator to control a coating operation includingselection of one or more operating parameters using one hand if sodesired, even the same hand that is being used to support or grip thespray gun, all without having to look away from the spray gun or thecoating area to verify selections made.

There is no necessary limitation on the functions and parameterselections that may be programmed for the display 100 or the auxiliarytrigger 70. Any functionality and parameter selections may be madeavailable as needed for a particular system. Also, the use of additionalauxiliary triggers or multi-position manual actuation devices canfurther increase the flexibility of the overall concepts describedherein. As another example, although successive actuation of theauxiliary trigger 70 may be used to step through options or incrementalchanges for one or more coating operation parameters, flow rate forexample, if the trigger is held down then the values may increment ingreater steps or faster, for example.

The control system 28 may also include a main or system display 140(FIG. 1) that may be used, for example, during system setup, calibrationand so on. This display 140, however, may or may not be located close tothe operator working area, or may not be visible to the operator duringa coating operation. The gun mounted display 100 may present some or allof the same information presented back at the system display 140.

To name just a few examples of alternative functionality, by appropriatesettings and programming if the control system 28 and the gun controller110, the auxiliary trigger 70 may be used to: adjust charging voltage upand down; adjust current limits up and down; adjust the presets of allthe guns in a system, including automatic guns, using a manual gun as amaster; and to initiate purge operations or color change operations.Color change operations may include operations and functions such as,for example, supply changeover, various purging operations, spray boothcleaning operations, overspray recovery operations, gun blow off and soon.

These are but a few of the many programmable or selectable functionsthat may be assigned to the auxiliary trigger 70. Additional options areavailable for the manual inputs 116 that are on the display 100. Forexample, these manually actuated inputs may have functionality assignedto them or programmed such as preset recipe select; initiate purgeoperation; a disable button, automatic gun triggers, and multiple flowcontrol modes. For flow control, two available and exemplary options areto use one of the manually actuated inputs 116 to present a choice of atraditional flow control mode or a total flow control adjustment mode.In the traditional flow control mode, the auxiliary trigger 70 may beused to adjust flow air or atomizing air settings independently of eachother. For example, in one input 116 mode the auxiliary trigger 70 maybe used to adjust flow air, and in another selected input 116 mode theauxiliary trigger 70 may be used to adjust atomizing air. In the totalflow control mode, an operator may select a total air flow setting viaan input function to the main controller 114 (or alternatively forexample total air flow may be selected as part of a preset recipeselection). The total air flow parameter may for example be used toselect the velocity of the coating material from the nozzle portion 12.The operator may then use the auxiliary switch 70 to select thepercentage or ratio of the total air flow that is to be flow air andatomizing air to achieve desired coating material velocity, flow rateand/or film deposition. Adjusting the ratio, for example, will notchange the velocity parameter but will change the amount of powder inthe coating material cloud that is produced from the spray gun 10. Thecontrol system 28 then sets the appropriate atomizing air value and flowair value based on the two selected input values of total air flow andselected ratio.

It should be noted that reference herein to parameters and values shouldnot be construed in a limiting sense. Parameters and values selected maybe actual data points based on empirical or predicted analysis, but alsomay be numbers, values or other data or information that representcoating operation parameters as to performance, effects and results,rather than representing actual data points. For example, a presetrecipe number can be thought of as a parameter or value that isselectable by the operator, but actually just represents or encodes oneor more settings, values and so on for a coating operation. As anotherexample, flow rate information presented to the operator on the display100 may be actual flow rate values as measured, or may instead beidentified as a scale, such as from 0% to 100% of total flow. Thus, thepresent disclosure should not be construed as requiring any particularformat or code or representation of the coating operation parameterchoices and selections or other information presented to the operatorvia the display 100 and selected via the manually actuated inputs 116and auxiliary trigger 70.

Note that as the manual inputs 116 are selected for differentfunctionality, the icons 130 and 132 may also be changed as appropriateto identify the functionality to the operator. For example, simpleoverlays may be used to change the icon figures that are illuminated bythe lamps 126 and 128.

Still further, in the exemplary embodiment or others, the system maincontroller 114 communicates with the spray gun mounted displaycontroller 110 via the network 112 or other suitable communication link.In such cases, the main controller 114 may be programmed to recognizerevision levels or other software and database information that thedisplay controller 110 is using, and may perform various programmingfunctions, such as for example, upload updates to the display controller110 as needed, or update or upload different programs that may be neededfor particular applications and configurations.

With reference to FIG. 7, an exemplary embodiment of a displaycontroller 110 and related circuits is illustrated. The displaycontroller 110 may be any suitable controller, such as a DSP circuit,for example, or other microcontroller, microprocessor, discrete circuitsand so on. Preferably the display controller 110 is programmable viasoftware as is well known generally in the art of programmable circuits,with appropriate memory and other peripheral support circuits. Thedisplay controller 110 may be disposed on one of the circuit boards 108(FIG. 4) and includes appropriate connections to the LED and displaydriver circuits 142. The display and driver circuit 142 may also receiveas inputs the connections to the manually actuated inputs 118 and 120.The display controller 110 may receive the inputs from the main triggerswitch 78 (FIG. 3) as well as the auxiliary trigger switches 96 and 98.The display controller 110 also provides communication with the controlsystem 28 main controller 114 via wiring bundle 144 (the network 114interface may be provided, for example, within the display controller110 software and circuitry, and the main controller 114 may also havebuilt in the necessary network interface functionality to communicatewith the display controller 110).

With reference to FIG. 8, in one embodiment of the control system 28,the main controller 114 may be any suitable device such as for example,a DSP type controller, microcontroller, microprocessor, discretecircuits and so on, and known or later developed software, hardware andfirmware programming may be used to implement the various functions andcontrols of the control system 28. The main controller 114 may interfacewith a Gun Driver circuit 146 and DC supply 148 that provides a drivesignal to the spray guns associated with the control system 28. In thisembodiment, the DC supply 148 is used to power a PWM drive signal forthe spray guns. The main controller also interfaces with the network 112for communication with the display controller 110. The main controller114 also interfaces via a serial peripheral interface circuit 150 a witha display driver circuit 150 for the system display 140 (FIG. 1). Thespray gun display 100 may receive some or all or different displayinformation as is presented on the main system display 140. For example,flow rates may be displayed on both, as well as selected preset numbers.How much common information is presented at the same time on bothdisplays is a matter of design choice. Additional information that maybe displayed on the spray gun display may include various warnings,alarms and so on.

The main controller 114 may also interface with a network 152 such as aCAN network for example, for systems that use multiple guns and otherequipment interconnected by a communication network, as is known. Otherinterfaces may include an external input such as a keypad or input knob156 to allow the operator to provide inputs to the controller 114. Forexample, it may be desired to adjust the recipe presets, or one or moreindividual parameters and controls assigned to a particular preset orpresets. Since the external input 156 may produce voltage and currenttransients, a transient voltage suppression circuit 158 may be used asneeded. Configurable (as in programmable or selectable) auxiliaryexternal inputs 160 may include, for example, conveyor control,automatic gun trigger controls, fire detection signals and so on. Sincethese inputs may include field wiring noise and transient spike issues,it may be desirable to use signal conditioning circuits 162 such asopto-isolators for example to protect the main controller 114 from sucheffects. The main controller 114 may also interface with a vibratory boxfeeder via a relay circuit 164 to turn the vibrator on and off asneeded. Still further, configuration switches such as DIP switches 166may be used for external configuration selection of the control system28, as well as an optional external programming interface 168. Manyother or alternative interfaces and control and configuration optionsmay be used as needed for a particular system, especially more complexsystems that involves manual and automatic guns, advanced spray booth,powder recovery and gun mover designs, and so on.

The inventions have been described with reference to the exemplaryembodiments. Modifications and alterations will readily occur to othersupon a reading and understanding of this specification and drawings. Itis intended to include all such modifications and alterations insofar asthey come within the scope of the appended claims or the equivalentsthereof.

The invention claimed is:
 1. A coating material spray gun, comprising: ahandle that is manually gripped with one hand by an operator during acoating operation, a trigger mounted on the handle, the triggercomprising a main body and a boss extending from the main body, and acompressible member that is coupled to the boss and that is at leastpartially located between the handle and the trigger that engages aswitch when the trigger is actuated.
 2. The coating material spray gunof claim 1, wherein the trigger further comprises two flexible armsextending from the main body, the flexible arms causing the main body toreturn to a non-actuated position when the trigger is released by anoperator.
 3. The coating material spray gun of claim 2, wherein each ofthe flexible arms is able to move the main body to a non-actuatedposition when the other arm is broken.
 4. The coating material spray gunof claim 1, wherein the trigger mounted on the handle is a first triggerthat is actuated by the one hand to start and stop the coatingoperation.
 5. The coating material spray gun of claim 4, furthercomprising a second trigger mounted on the handle that is actuated bythe one hand.
 6. The coating material spray gun of claim 5, furthercomprising a display disposed on or with a portion of the coatingmaterial spray gun.
 7. The coating material spray gun of claim 6,wherein the second trigger is actuated to change a coating operationparameter displayed on the display.
 8. The coating material spray gun ofclaim 6, wherein two or more sets of coating material parameter valuesare displayed on the display, and wherein the second trigger is actuatedto select one of the two or more sets of coating material parametervalues.
 9. The coating material spray gun of claim 8, wherein the secondtrigger is actuated to scroll through the two or more displayed sets ofcoating material parameter values to select one of the two or more setsof coating material parameter values.
 10. The coating material spray gunof claim 6, wherein the second trigger has a neutral position, a firstactuated position and a second actuated position.
 11. The coatingmaterial spray gun of claim 10, wherein the second trigger is configuredto be moved to the first actuated position to scroll in a firstdirection through the displayed two or more sets of coating materialparameter values, and is configured to be moved to the second actuatedposition to scroll in a second direction, which is opposite the firstdirection, through the displayed two or more sets of coating materialparameter values.
 12. The coating material spray gun of claim 10,wherein the second trigger is configured to be pivoted in one directionto the first actuated position and pivoted in the opposite direction tothe second actuated position.
 13. The coating material spray gun ofclaim 10, wherein the second trigger is configured to be moved to thefirst actuated position to increase a flow rate of coating materialthrough the coating material spray gun and is configured to be moved tothe second actuated position to decrease the flow rate of coatingmaterial through the coating material spray gun.
 14. The coatingmaterial spray gun of claim 10, wherein the second trigger is configuredto be moved between the neutral position and the first and secondactuated positions to change a value of a coating operation parameter.15. The coating material spray gun of claim 5, wherein the secondtrigger is used to increase and decrease the flow rate of coatingmaterial through the coating material spray gun.
 16. The coatingmaterial spray gun of claim 5, wherein the second trigger is actuated bythe one hand to select one or more coating operation parameter values.17. A coating material spray gun, comprising: a handle that is manuallygripped with one hand by an operator during a coating operation; atrigger mounted on the handle having a main body and two flexible armsextending from the main body, the flexible arms configured to cause themain body to return to a non-actuated position when the trigger isreleased by an operator; and a compressible member mounted on thetrigger, the compressible member being longitudinally compressible. 18.The coating material spray gun of claim 17, wherein each of the flexiblearms is able to move the main body to a non-actuated position when theother arm is broken.
 19. The coating material spray gun of claim 17,wherein the compressible member is between the handle and the triggerand engages a switch when the trigger is actuated.
 20. The coatingmaterial spray gun of claim 1, wherein the compressible member islongitudinally compressible.